workshop manual kd 500 - lombardini s.r.l....kohler co. warrants to the original retail consumer...

KD 500

WORKSHOP MANUAL

CUSE/ATLO

Drafting body

Document code Edition Issue date

Review date

ModelN° Revision Endorsed

PREFACE

- Everyattempthasbeenmadetopresentwithinthisservicemanual,accurateanduptodatetechnicalinformation. However,developmentontheKOHLERseriesiscontinuous. Therefore,theinformationwithinthismanualissubjecttochangewithoutnoticeandwithoutobligation. The materials used by KOHLER to construct the engine's components undergo strict quality controls and the engine'sassemblyguaranteesreliabilityandlonglife.

Theenginehasbeenbuilttothemachinemanufacturer'sspecifications,anditwasitsresponsibilitytoadoptallthemeasuresneededtomeettheessentialhealthandsafetyrequirementsasprovidedforbythelawsinforce;useoftheengineforusesotherthantheonedefinedshallnotbeconsideredascompliantwiththeuseintendedbyKOHLER,whothereforerefusesallresponsibilityforanyinjuryarisingfromsuchanoperation.

- TheinformationcontainedwithinthisservicemanualisthesolepropertyofKOHLER. Assuch,noreproductionorreplicationinwholeorpartisallowedwithouttheexpresswrittenpermissionofKOHLER.

Informationpresentedwithinthismanualassumesthefollowing:

1 - ThepersonorpeopleperformingserviceworkonKOHLERseriesenginesisproperlytrainedandequippedtosafelyandprofessionallyperformthesubjectoperation;

2 - The person or people performing service work on KOHLER series engines possesses adequate hand and KOHLERspecialtoolstosafelyandprofessionallyperformthesubjectserviceoperation;

3 - ThepersonorpeopleperformingserviceworkonKOHLERseriesengineshasreadthepertinentinformationregardingthesubjectserviceoperationsandfullyunderstandstheoperationathand.

- ThismanualwaswrittenbythemanufacturertoprovidetechnicalandoperatinginformationtoauthorisedKOHLERafter-salesservicecentrestocarryoutassembly,disassembly,overhauling,replacementandtuningoperations.

- Aswell asemployinggoodoperating techniques andobserving the right timing for operations, operatorsmust read theinformationverycarefullyandcomplywithitscrupulously.

- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandfinancialdamage. Writteninformationisaccompaniedbyillustrationsinordertofacilitateyourunderstandingofeverystepoftheoperatingphases.

KD 500

1° 0 04/07/201204/07/2012ED0053029390 51267

REGISTRATION OF MODIFICATIONS TO THE DOCUMENTAnymodificationstothisdocumentmustberegisteredbythedraftingbody,bycompletingthefollowingtable.

- 3 - - 3 -

-

Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00

WARRANTY CERTIFICATE

LIMITED 3 YEAR KOHLER® DIESEL ENGINE WARRANTY

KohlerCo.warrantstotheoriginalretailconsumerthateachnewKOHLERDieselenginesoldbyKohlerCo.willbefreefrommanufacturingdefects inmaterialsorworkmanship innormal service foraperiodof three (3) yearsor2000hourswhicheveroccurs first from thedateofpurchase,providedit isoperatedandmaintainedinaccordancewithKohlerCo.’s instructionsandmanuals. Ifnohourmeter is installedasoriginalequipmentthen8hoursofuseperdayand5daysperweekwillbeusedtocalculatehoursused.

Ourobligationunderthiswarrantyisexpresslylimited,atouroption,tothereplacementorrepairatKohlerCo.,Kohler,Wisconsin53044,orataservicefacilitydesignatedbyusofsuchpartsasinspectionshalldisclosetohavebeendefective.

Thiswarrantydoesnotapplytodefectscausedbyunreasonableuse,includingfaultyrepairsbyothersandfailuretoprovidereasonableandnecessarymaintenance.

Thefollowingitemsarenotcoveredbythiswarranty:Engineaccessoriessuchasfueltanks,clutches,transmissions,power-driveassembliesandbatteries,unlesssuppliedorinstalledbyKohlerCo.Thesearesubjecttothewarranties,ifany,oftheirmanufacturers.

KOHLERCO.AND/ORTHESELLERSHALLNOTBELIABLEFORSPECIAL,INDIRECT,INCIDENTIALORCONSEQUENTIALDAMAGESOFANYKIND,includingbutnotlimitedtolaborcostsortransportationchargesinconnectionwiththerepairorreplacementofdefectiveparts.

IMPLIEDORSTATUTORYWARRANTIES,INCLUDINGWARRANTIESOFMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE,AREEXPRESSLYLIMITEDTOTHEDURATIONOFTHISWRITTENWARRANTY.Wemakenootherexpresswarranty,norisanyoneauthorizedtomakeanyonourbehalf.

Somestatesdonotallowlimitationsonhowlonganimpliedwarrantylasts,ortheexclusionorlimitationofincidentalorconsequentialdamages,sotheabovelimitationorexclusionmaynotapplytoyou.

Thiswarrantygivesyouspecificlegalrights,andyoumayalsohaveotherrights,whichvaryfromstatetostate.

Toobtainwarrantyservice

PurchasermustbringtheenginetoanauthorizedKohlerservicefacility.Tolocatethenearestfacility,visitourwebsite,www.kohlerengines.com,andusethelocatorfunction,consultyourYellowPagesortelephone1-800-544-2444.

ENGINEDIVISION,KOHLERCO.,KOHLER,WISCONSIN53044

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board andKohlerCo.arepleasedtoexplaintheemission control system warrantyonyour2012engine.InCalifornia,newheavy-dutyoff-roadenginesmustbedesigned,builtandequippedtomeettheState’sstringentanti-smogstandards.KohlerCo.mustwarranttheemissioncontrolsystemonyourengineforthetimeperiodlistedbelowprovidedtherehasbeennoabuse,neglectorimpropermaintenanceofyourengine.Youremissioncontrolsystemmay includepartssuchasthefuel-injectionsystemandtheair inductionsystem.Also includedmaybehoses,connectorsandotheremissionrelatedassemblies.Whereawarrantableconditionexists,KohlerCo.willrepairyourheavy-dutyoff-roadengineatnocosttoyouincludingdiagnosis,partsandlabor.

MANUFACTURER’S WARRANTY COVERAGE:

Youroff-road,dieselengineemissioncontrolsystemiscoveredunderwarrantyforaperiodoffive(5)yearsor3,000hours,whicheveroccursfirst,beginningonthedatetheengineorequipmentisdeliveredtoanultimatepurchaserforallconstantspeedengineswithmaximumpower19≤kW<37andratedspeedlessthan3,000rpm,allvariablespeedengineswithmaximumpower19≤kW<37,andallvariableorconstantspeedengineswithmaximumpowergreaterthan37kW.Youroff-road,dieselengineemissioncontrolsystemonvariableorconstant-speedengineswithmaximumpowerlessthan19kW,andforconstantspeedengineswithmaximumpower19≤kW<37andratedspeedequaltoorgreaterthan3,000rpmiscoveredunderwarrantyforaperiodoftwo(2)yearsor1,500hours,whicheveroccursfirst.Ifanyemissionrelatedpartonyourengineisdefective,thepartwillberepairedorreplacedbyKohlerCo.

OWNER’S WARRANTY RESPONSIBILITIES:

As theheavy-dutyoff-roadengineowner,youare responsible for theperformanceof the required maintenance listed in your Kohler Co. owner’s manual.KohlerCo.recommendsthatyouretainallreceiptscoveringmaintenanceonyourheavy-dutyoff-roadengine,butKohlerCo.cannotdenywarrantysolelyforthelackofreceiptsorforyourfailuretoensuretheperformanceofallrecommendedscheduledmaintenance.Astheheavy-dutyoff-roadengineowner,youshouldhoweverbeawarethatKohlerCo.maydenyyouwarrantycoverageifyourheavy-dutyoff-roadengineoremissioncontrolrelatedcomponenthasfailedduetoabuse,neglect,impropermaintenanceorunapprovedmodifications.Yourengineisdesignedtooperateoncommercialdieselfuel(No.1orNo.2lowsulfurorultralowsulfurdieselfuel)only.UseofanyotherfuelmayresultinyourenginenolongeroperatingincompliancewithCalifornia’semissionsrequirements.Youareresponsibleforinitiatingthewarrantyprocess.TheAirResourcesBoardsuggeststhatyoupresentyourheavy-dutyoff-roadenginetoaKohlerCo.dealerassoonasaproblemexists.Thewarrantyrepairsshouldbecompletedbythedealerasexpeditiouslyaspossible.Pleasereviewthedocumenttitled,“KohlerCo.FederalandCaliforniaEmissionControlSystemsLimitedWarrantyOff-RoadDieselEngines”,forcompletedetailsofyourheavy-dutyoff-roadenginewarranty.IfyouhaveanyquestionsregardingyourwarrantyrightsandresponsibilitiesorthelocationofthenearestKohlerCo.authorizedservicelocation,youshouldcontactKohlerCo.at1-800-544-2444oraccessourwebsiteatwww.kohlerengines.com.

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- INDEX


INDEX

WARRANTY CERTIFICATE ..................................................................................................................................... 3Limited3yearkohler®dieselenginewarranty.................................................................................................................. 3Californiaemissioncontrolwarrantystatement................................................................................................................. 3

TROUBLE SHOOTING .............................................................................................................................................. 7POSSIBLECAUSESANDTROUBLESHOOTING........................................................................................................... 7

GENERAL REMARKS AND SAFETY INFORMATION ........................................................................................... 8SAFETYREGULATIONS................................................................................................................................................... 8GENERALSAFETYDURINGOPERATINGPHASES...................................................................................................... 9SAFETYANDENVIRONMENTALIMPACT..................................................................................................................... 9

MODEL NUMBER AND IDENTIFICATION ............................................................................................................. 10Theidentificationplateshowninthefigurecanbefounddirectlyontheengine..............................................................10Approvaldata.....................................................................................................................................................................10

TECHNICAL DATA .................................................................................................................................................. 11ENGINETYPE...................................................................................................................................................................11

CHARACTERISTICS ............................................................................................................................................... 12CHARACTERISTICSPOWER,TORQUEANDSPECIFICFUELCONSUMPTIONCURVES.......................................12

OVERALL DIMENSIONS ........................................................................................................................................13

SPECIAL TOOLS .................................................................................................................................................... 14

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ...................................................................... 15MAINTENANCE.................................................................................................................................................................15FUEL..................................................................................................................................................................................15RECOMMENDEDOIL.......................................................................................................................................................16ACEASEQUENCES..........................................................................................................................................................16

DISASSEMBLY OF THE ENGINE .......................................................................................................................... 17DISASSEMBLYANDREASSEMBLY................................................................................................................................17Removingtheinjector........................................................................................................................................................17Removingtheinjectionpump............................................................................................................................................17Flywheelextraction............................................................................................................................................................17Removingthecoveronthetimingsystemside.................................................................................................................17Demountingthepiston.......................................................................................................................................................18Demountingandremountingthemainbearings...............................................................................................................18

CHECKS AND OVERHAUL .................................................................................................................................... 19Head...................................................................................................................................................................................19Valves-Guides-Housings...............................................................................................................................................19Valvesprings..................................................................................................................................................................... 20Cylinder............................................................................................................................................................................. 20Pistonrings-Piston-Pin..................................................................................................................................................21Connectingrod..................................................................................................................................................................21Crankshaft........................................................................................................................................................................ 22Oilretentionrings.............................................................................................................................................................. 22Lubricationcircuit.............................................................................................................................................................. 22Checkingtheoilpump...................................................................................................................................................... 23Camshaft........................................................................................................................................................................... 23Tapetsandrockerarms.................................................................................................................................................... 24Injectionpumptappetsandpads...................................................................................................................................... 24Fuelpump(optional)......................................................................................................................................................... 24

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-Index


INJECTION EQUIPMENT ....................................................................................................................................... 25Fuelcircuit......................................................................................................................................................................... 25Injectionpump.................................................................................................................................................................. 25Injectionpumpcalibration................................................................................................................................................. 26Injectionpumpassembly.................................................................................................................................................. 26Leaktest............................................................................................................................................................................ 27Injectorinspectionandcalibration.................................................................................................................................... 27

ELECTRICAL EQUIPMENT .................................................................................................................................... 29Characteristicsofthesystem........................................................................................................................................... 29Checkingthesystem........................................................................................................................................................ 29Checkingthealternator..................................................................................................................................................... 30Ringgear.......................................................................................................................................................................... 30

ENGINE ASSEMBLY ............................................................................................................................................... 31Preparingtheengineblock................................................................................................................................................31Injectionpumptappets......................................................................................................................................................31Timingsystemcoverpre-assembly.................................................................................................................................. 32Removalandassemblyofthedriveshaftgear................................................................................................................ 33Driveshaftassembly........................................................................................................................................................ 33Connectingrod-driveshaftconnection.......................................................................................................................... 33Counter-shaft.................................................................................................................................................................... 33Camshaft........................................................................................................................................................................... 34Playadjustment................................................................................................................................................................ 34Crankshaftfloat:................................................................................................................................................................ 34Camshaftfloat:.................................................................................................................................................................. 34Counter-shaftfloat(optional):........................................................................................................................................... 35Coverontimingsystemside............................................................................................................................................. 35Oilretentionrings.............................................................................................................................................................. 35Flywheel............................................................................................................................................................................ 35Piston................................................................................................................................................................................ 36Cylinder............................................................................................................................................................................. 36Head.................................................................................................................................................................................. 36Valveclearance................................................................................................................................................................ 37Injectionlead..................................................................................................................................................................... 37Mountingtheinjectionpumpontheengine...................................................................................................................... 38Injectorandinjectortube.................................................................................................................................................. 38

ENGINE TESTING ................................................................................................................................................... 39Rpmregulation................................................................................................................................................................. 39Brakedenginetest............................................................................................................................................................ 39Temporaryprotection(1/6months)................................................................................................................................... 40Permanentprotection(over6months)............................................................................................................................. 40Howtopreparetheengineforoperation.......................................................................................................................... 40

STORAGE ............................................................................................................................................................... 40

QUICK REFERENCE CHARTS .............................................................................................................................. 41

SERVICE ................................................................................................................................................................. 43SUGGESTIONSONHOWTOTIMETHEINJECTIONPUMPWHENTHELEADPUNCHMARKSONTHEFLYWHEELAREDIFFICULTTOREACH....................................................................................................................... 43

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- Index


- 7 - - 7 -

1POSSIBLE CAUSES AND TROUBLE SHOOTING

Thefollowingtablecontainsthepossiblecausesofsomefailureswhichmayoccurduringoperation.Alwaysperformthesesimplechecksbeforeremovingorreplacinganypart.

POSSIBLE CAUSE

TROUBLE

Oilandfuel

drippingfrom

exhaust

Increaseoillevel

Toolowoilpressure

Whitesmoke

Blacksmoke

Non-uniformspeed

Noacceleration

Enginestartsbutstops

Enginedoesnotstart

Excessiveoil

consumption

FUEL

CIR

CU

ITLU

BR

ICAT

ION

ELEC

TRIC

SY

STEM

MA

INTE

-N

AN

CE

SETT

ING

S/R

EPA

IRS

Cloggedpipes

Cloggedfuelfilter

Airinsidefuelcircuit

Cloggedtankbreatherhole

Faultyfuelpump

Injectorjammed

Jammedinjectionpumpdeliveryvalve

Wronginjectorsetting

Excessiveplungerblow-by

Jammedinjectionpumpdeliverycontrol

Wronginjectionpumpsetting

Oilleveltoohigh

Jammedpressurereliefvalve

Wornoilpump

Airinsideoilsuctionpipe

Faultypressuregaugeorswitch

Cloggedoilsuctionpipe

Batterydischarged

Wrongorinefficientcableconnection

Defectiveignitionswitch

Defectivestartermotor

Cloggedairfilter

Excessiveidleoperation

Incompleterunning-in

Engineoverloaded

Advancedinjection

Delayedinjection

Incorrectgovernorlinkageadjustment

Brokenorloosegovernorspring

Idlespeedtoolow

Wornorjammedpistonrings

Wornorscoredcylinders

Wornvalveguides

Jammedvalves

Wornbearings

Governorlinkagenotfreetoslide

Driveshaftnotfreetoslide

Damagedcylinderheadgasket

TROUBLE SHOOTING


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2 GENERAL REMARKS AND SAFETY INFORMATION


GENERAL NOTES

. Kohler engines are built to provide safe and longlastingperformances, but in order to obtain these results it isessential that the maintenance requirements described inthe manual are observed along with the following safetyrecommendations.

. The engine has been built to the specifications of amachinemanufacturer,anditishisresponsibilitytoensurethat all necessary action is taken to meet the essentialand legally prescribed health and safety requirements.Any use of themachine other than that described cannotbe considered as complying with its intended purposeas specified by Kohler, which therefore declines allresponsibilityforaccidentscausedbysuchoperations.

. The following instructions are intended for the user of themachine in order to reduce or eliminate risks, especiallythoseconcerning theoperationandstandardmaintenanceoftheengine.

. The user should read these instructions carefully and gettoknowtheoperationsdescribed.Bynotdoingsohemayplaceatriskhisownhealthandsafetyandthatofanyoneelseinthevicinityofthemachine.

. The enginemay be used ormounted on amachine onlybypersonnelsuitably trained in itsoperationandawareofthedangers involved.This is particularly true for standardand, above all, special maintenance work. For specialmaintenance contact personnel trained specifically byKohler.Thisworkshouldbecarriedoutinaccordancewithexistingliterature.

. Kohlerdeclinesallresponsibilityforaccidentsorforfailuretocomplywiththerequirementsoflawifchangesaremadetotheengine’sfunctionalparametersortothefuelflowrateadjustments and speed of rotation, if seals are removed,or ifpartsnotdescribed in theoperatingandmaintenancemanual are removed and reassembled by unauthorizedpersonnel.

WARNING

. Inaddition toall othermachinespecifications,ensure thattheengine is inanearhorizontalpositionwhenstarting. lfstarting manually, ensure that the necessary operationscanbeperformedwithoutanyriskofstrikingagainstwallsordangerousobjects.Ropestarting(exceptforrecoilropestarting)isnotpermittedeveninemergencies.

. Checkthatthemachineisstablesothatthereisnoriskofitoverturning.

. Get to know the engine speed adjustment and machinestopoperations.

. Do not start the machine in closed or poorly ventilatedenvironments.The internal combustion process generatescarbon monoxide, an odourless and highly toxic gas, sospending too long a time in an environment where theengine discharges its exhaust products freely can lead tolossofconsciousnessandevendeath.

. The engine may not be used in environments containingflammable materials, explosive atmospheres or easilycombustible powders, unless adequate and specificprecautions have been taken and are clearly stated andcertifiedforthemachine.

. Topreventtheriskoffire,keepthemachineatadistanceofatleastonemetrefrombuildingsorothermachines.

SAFETY REGULATIONS

. Children and animals must be kept at a sufficient distancefrom the machine to prevent any danger resulting from itsoperation.

. Fuel is flammable, so the tankmust be filled only when theengine is turned off. Dry carefully any fuel that may havespilled, remove the fuel container and any cloths soakedin fuel or oil, check that any sound-absorbing panels madeofporousmaterial arenot soakedwith fueloroil, andmakesurethatthegroundonwhichthemachineislocatedhasnotabsorbedfueloroil.

. Before starting, remove any tools that have been used forcarrying out maintenance work to the engine and/or themachine and check that any guards removed have beenreplaced. Incoldclimates it ispossible tomixkerosenewiththediesel fuel tomaketheengineeasier tostart.Theliquidsmust be mixed in the tank by pouring in first the keroseneand then the diesel fuel. ConsultKohler technical office formixture proportions. Petrolmay not be used because of theriskofitformingflammablevapours.

. During operation the surface of the engine reachestemperatures thatmaybe dangerous. Avoid in particular allcontactwiththeexhaustsystem.

. The liquid cooling circuit is underpressure.Donot carryoutany checks before the engine has cooled down, and eventhenopen the radiator capor theexpansion tank cautiously.Wear protective clothing and glasses. lf there is an electricfan,donotapproachtheenginewhile it isstillhotasthefanmaycomeonevenwhentheengineisnotrunning.Cleanthecoolingsystemwiththeengineturnedoff.

. While cleaning the oil bath air filter, check that the oil isdisposed of in such a way as not to harm the environment.Any filtering sponges in the oil bath air filter should not besoakedwithoil. Thecyclonepre-filtercupmustnotbefilledwithoil.

. Sincetheoilmustbeemptiedoutwhiletheengineisstillhot(approx. 80°C), particular care should be taken in order toavoid burns. In any casemake sure that oil does not comeinto contact with your skin because of the health hazardsinvolved.

. Fuelvapoursarehighlytoxic,sofilluponlyintheopenairorinwellventilatedenvironments.

. During operations which involve access to moving parts ofthe engine and/or removal of the rotary guards, disconnectandinsulatethepositivecableofthebatterysoastopreventaccidentalshortcircuitsandactivationofthestartermotor.

. Checkthebelttensiononlywhentheengineisturnedoff.

IMPORTANT

. To start the engine follow the specific instructions providedin the engine and/or machine operating manual. Do notuse auxiliary starting devices not originally installed on themachine(e.g.Startpilotsystemswhichutiliseetheretc.)

. Before carrying out any work on the engine, turn it off andallowittocooldown.Donotperformanyoperationwhiletheengineisrunning.

. Check that the discharged oil, the oil filter and the oilcontainedintheoilfilteraredisposedofinsuchawayasnottoharmtheenvironment.

. Close the fuel tank filler cap carefully after each fíllingoperation. Do not fill the tank right up to the top, but leavesufficientspacetoallowforanyexpansionofthefuel.

. Donotsmokeorusenakedflameswhilefilling.

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2

GENERAL SAFETY DURING OPERATING PHASES

– Theprocedurescontainedinthismanualhavebeentestedandselectedbythemanufacturer’stechnicalexperts,andhencearetoberecognisedasauthorisedoperatingmethods.

– Sometoolsarenormalworkshopones,whileothersarespecialtoolsdesignedbytheManufactureroftheengine.

– Alltoolsmustbeingoodworkingconditionsothatenginecomponentsarenotdamagedandthatoperationsarecarriedoutproperlyandsafely.

– Itisimportanttowearthepersonalsafetydevicesprescribedbyworksafetylawsandalsobythestandardsofthismanual.

– Holesmustbelinedupmethodicallyandwiththeaidofsuitableequipment.Donotuseyourfingerstocarryoutthisoperationtoavoidtheriskofamputation.

SAFETY AND ENVIRONMENTAL IMPACT

Everyorganisationhasadutytoimplementprocedurestoidentify,assessandmonitortheinfluenceofitsownactivities(products,services,etc.)ontheenvironment.Proceduresforidentifyingtheextentoftheimpactontheenvi-ronmentmustconsiderthefollowingfactors:

- Liquidwaste; - Wastemanagement; - Soilcontamination; - Atmosphericemissions; - Useofrawmaterialsandnaturalresources; - Regulationsanddirectivesregardingenvironmentalimpact.

Inordertominimisetheimpactontheenvironment,themanufacturernowprovidesanumberofindicationstobefollowedbyallpersonshandlingtheengine,foranyreason,duringitsexpectedlifetime.

- Allpackagingcomponentsmustbedisposedofinaccordancewiththelawsofthecountryinwhichdisposalistakingplace.

- Keep the fuel and engine control systems and the exhaustpipesinefficientworkingordertolimitenvironmentalandnoisepollution.

- Whendiscontinuinguseoftheengine,selectallcomponentsaccordingtotheirchemicalcharacteristicsanddisposeofthemseparately.

– Somephasesmayrequiretheassistanceofmorethanoneoperator.Ifso,itisimportanttoinformandtrainthemregardingthetypeofactivitytheywillbeperforminginordertopreventriskstothehealthandsafetyofallpersonsinvolved.

– Donotuseflammableliquids(petrol,diesel,etc.)todegreaseorwashcomponents.Usespecialproducts.

– Usetheoilsandgreasesrecommendedbythemanufacturer. Donotmixdifferentbrandsorcombineoilswithdifferent

characteristics.– Discontinueuseoftheengineifanyirregularitiesarise,

particularlyinthecaseofunusualvibrations.– Donottamperwithanydevicestoalterthelevelof

performanceguaranteedbythemanufacturer.

California Proposition 65WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

General remarks and safety information


. Takecarewhenremovingtheoilfilterasitmaybehot.

. The operations of checking, filling up and replacing thecoolingliquidmustbecarriedoutwiththeengineturnedoffandcold. Takeparticular care if liquids containingnitritesare mixed with others not containing these compoundsas this may give rise to the formation of nitrosamineswhichareahealthhazard. Thecooling liquid ispolluting,so dispose of in a manner that does not damage theenvironment.

. In order to move the engine simultaneously use theeyebolts fitted for this purpose by Kohler. These liftingpointsarehowevernotsuitable for theentiremachine,sointhiscaseusetheeyeboltsfittedbythemanufacturer.

- 10 -

3


The identification plate shown in the figure can be found directly on the engine.

Itcontainsthefollowinginformation:

A)Manufacturer’sidentityB)EnginetypeC)EngineserialnumberD) MaximumoperatingspeedE) Numberofthecustomerversion(formK)F)Approvaldata

Approval data

TheapprovalreferencedirectivesECareontheengineplate(F).

C

A

F

D

E

B

MODEL NUMBER AND IDENTIFICATION

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4

KD 500N° 1mm 87mm 85Cm3 505

19:1N80/1269/CEE-ISO15859(12.24) 9(12,24)(HP)NBISO3046-1IFN8.4(11.42) 8,4(11,42)NAISO3046-1ICXN7.6(10.34) 7,6(10,34)

rpm 3600rpm 3000

Nm(@rpm) 31(2000)g/kWh 250kg/h 0,0055

lt 1,5Ah-A 50Ah-255ADINAh-A 60Ah-300ADIN

kg 48l/min 800l/min 8700kg 120(300)

30°(35°)35°(45°)

30°(40°)

30°(45°)

ENGINE TYPE

PowerkW

Max.inclination

*ViewedtheenginefrommainP.T.O.

NumberofcylindersBoreStrokeSweptvolumeCompressionratio

CrankshaftPTOratioCamshaftPTOratioCrankshaftmainPTOrotationCamshaftmainPTOrotationMax.torqueFuelconsumption(@max.torque)OilconsumptionCapacityofstandardoilsumpRecommendedbattery12VinstandardstartconditionsRecommendedbattery12Vinheavy-dutystartconditionsDryweightCombustionairvolumeCoolingairvolumeMax.permissibledrivingshaftaxial:oncrankshaftmainPTO:continuous(instantaneous)

Flywheelsite:continuous(instantaneous)Powertakeoffsite:continuous(instantaneous)

Bankanglerightside:continuous(instantaneous)

Bankangleleftside:continuous(instantaneous)

right*left*


TECHNICAL DATA

- 12 -

5


CHARACTERISTICS

KD 500

N (80/1269/EEC - ISO 1585) AUTOMOTIVE RATING : Intermittentoperationwithvariablespeedandvariableload.NB (ISO 3046 - 1 IFN) RATING WITH NO OWERLOAD CAPABILITY: continuosligthdutyoperationwithconstantspeedandvariableload.NA (ISO 3046 - 1 ICXN) CONTINUOS RATING WITH OVERLOAD CAPABILITY: continuosheavydutywithconstantspeedandconstantload.MN TorqueatNpower.MB TorqueatNBpower.MA TorqueatNApower.C SpecificfuelconsumptionatNBpower.

Theabovepowervaluesrefertoanenginefittedwithaircleanerandstandardmuffler,aftertestingandattheenvironmentalconditionsof20°Cand1bar.Max.powertoleranceis5%.Powerdecreasesbyapproximately1%every100mdialtitudeandby2%every5°Cabove25°C.

Note:ConsultKOHLERforpower,torquecurvesandspecificconsumptionsatratesdifferingfromthosegivenabove.

CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES

- 13 - - 13 -

6

STANDARDP.T.O.WITHANTICLOCKWISEDIRECTIONOFROTATION

OPTIONALP.T.O.ONCAMSHAFTWITHCLOCKWISEDIRECTIONOFROTATION

* GRAVITYCENTEROFTHEENGINE AUXILIARY P.T.O. FOR HYDRAULICPUMPS


Note:Dimensionsinmm

OVERALL DIMENSIONS

- 14 -

7

00365R0020

00365R0900

00366R0220

00366R0230

00365R0770

00365R0100

00366R0210

00365R0430

00366R0240

00365R0940

TOOL CODE DESCRIPTION

SPECIAL TOOLS

FailureFlywheelpuller

Tooltomountanddemountmainbearings

Plugtomountanddemountmainbearings

Sleevetoinsertmainbearings

Pistonmountingtool

Crankshaftgearpuller

PunchtoinsertBy-passvalve

Injectortestbench

Tooltostaggerinjectionlead

Capillarytubeforinjectionlead


- 15 - - 15 -

10 50(1) 250(2) 500(3) 2500 5000

8MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

Failuretocarryouttheoperationsdescribedinthetablemayleadtotechnicaldamagetothemachineand/orsystem

(1)Afterthefirst50workinghours(2)Incaseoflowuse:every6months(3)Incaseoflowuse:every12months(4)Ifyouareusingoilofaqualitylowerthantherecommendedonethenyouwillhavetoreplaceitevery150hours

Themaintenanceoperations listedaboverefer toanengineoperating innormalconditions(temperature,degreeofhumidity,dustintheworkingenvironment).Theymayvarysignificantlyaccordingtothetypeofuse.

Toavoidexplosionsorfireoutbreaks,donotsmokeorusenakedflamesduringtheoperations.Fuelvapoursarehighlytoxic.Onlycarryouttheoperationsoutdoorsorinawellventilatedplace.Keepyourfacewellawayfromtheplugtopreventharmfulvapoursfrombeinginhaled.Disposeoffuelinthecorrectwayanddonotlitterasitishighlypolluting.

FUEL

Whenrefuelling,itisadvisabletouseafunneltopreventfuelfromspillingout.Thefuelshouldalsobefilteredtopreventdustordirtfromenteringthetank.Usethesametypeofdieselfuelasusedincars.Useofothertypesoffuelcoulddamagetheengine.Thecetaneratingofthefuelmustbehigherthan45topreventdifficultstarting.Donotusedirtydieselfuelormixturesofdieselfuelandwatersincethiswouldcauseseriousenginefaults.

Thecapacityofthestandardtankis:lt.5,0

INTERVAL (HOURS)OPERATION

MAINTENANCE

SUMPOILLEVELCHECKOILBATHAIRCLEANERCLEANINGDRYAIRCLEANERCHECKINGOILCARTERREPLACEMENT(4)OILFILTERREPLACEMENTFUELFILTERREPLACEMENTCOOLINGFINSCLEANINGSETTINGROCKERARMSCLEARANCESETTINGANDINJECTORSCLEANINGOVERALLINSPECTIONPARTIALOVERALLINSPECTIONCOMPLETE


- 16 -

-30

-25

-20

-15

-10

-5 0

+5

+10

+15

+20

+25

+30

+35

+40

+45

SAE 20WSAE 10W

+50

SAE 30SAE 40

SAE 10W-30SAE 10W-40

SAE 10W-60SAE 15W-40 base minerale

SAE 15W-40 base semi-sintetica

SAE 20W-60 base semi-sintetica

SAE 5W-30 base sintetica



-35

-40

CCMC G- 2

CF CE CD CC CB CA SA SB SC SD SE SF SG

DIESEL BENZINA - ESSENCE - PETROL BENZIN - GASOLINA

CCMC G- 3 G- 5CCMC PD - 1 / PD - 2

CCMC D- 2D- 4CCMC D- 3D- 5

MIL - L - 2104 DMIL - L - 2104 E

MIL - L -46152 CMIL - L- 46152 D/E

MB 226.1 MB 226.5MB 227.1 MB 227.5

228.3 MB 228.1

VW 501.01VW 500.00

SHAPIG- 4

SJ

VOLVO VDSMAN QC 13-017

VW 505.00

8 Maintenance - Recommended oil type - Refilling

Theenginecouldbedamagedifallowedtooperatewithinsufficientoil.Itisalsodangeroustoaddtoomuchoilasitscombustioncouldsharplyincreasetherotationspeed.Useasuitableoilinordertoprotecttheengine.Thelubricationoilinfluencestheperformancesandlifeoftheengineinanincredibleway.Theriskofpistonseizure,jammedpistonringsandrapidwearofthecylinderliner,thebearingsandallmovingpartsincreasesifoilwhosecharacteristicsdifferfromtherecommendedtypeisused,oriftheoilisnotregularlychanged.Allthisnotablyreducesenginelife.Oilviscositymustsuittheambienttemperatureinwhichtheengineoperates.

Oldoilcancauseskincancerifrepeatedlyleftincontactwiththeskinandforlongperiodsoftime.Ifcontactwiththeoilisinevitable,youareadvisedtothoroughlywashyourhandswithsoapandwaterassoonaspossible.Appropriateprotectiveglovesetcshouldbeworeduringthisoperation.Oldoilishighlypollutingandmustbedisposedofinthecorrectway.Donotlitter.

GRADERECOMMENDED OIL

AGIPSINT20005W40specificationAPISJ/CFACEAA3-96B3-96MIL-L-46152D/E.ESSOULTRA10W40 specificationAPISJ/CFACEAA3-96MIL-L-46152D/E.In countries whereAGIP and ESSO products are not available,useAPISJ/CFoilforgasoline-fuelledenginesoroilthatcomplieswithmilitaryspecificationMIL-L-46152D/E.

OIL SUPPLY ( liters )Standard oil sump

filter included 1,5 l.

ACEA SEQUENCES

A=Gasoline(Petrol)B=LightDieselfuelsE=HeavyDieselfuels

Requiredlevels:

A1-96 A2-96 A3-96

B1-96 B2-96 B3-96

E1-96 E2-96 E3-96


- 17 - - 17 -

4

3

2

1

9DISASSEMBLY OF THE ENGINE

Duringrepairoperations,whenusingcompressedair,weareyeprotection.

DISASSEMBLY AND REASSEMBLY

Besides disassembly and reassembly operations this chapteralsoincludescheckingandsettingspecifications,dimensions,repairandoperating instructions.AlwaysuseoriginalKOHLERsparepartsforrepairoperations.

Removing the injectorSlackenoffthefueldeliverypipe,removethefixingbracketandtakeoutthetube.Remove the injector by levering it out with a screwdriver, asindicatedinfig.1.

Removing the injection pumpMarkthepositionoftheinjectionpumpinrelationtotheenginecasing(ifthishasnotalreadybeendone).Removetheinjectiontubeandtakeoutthefuelpipes.Thepumpcanonlybe removedwhen thestop leverhasbeenturnedtothestopposition.Todothis,thepumpmustbepressedtowardsthehousingasshowninfig.2.

Flywheel extractionRemovethefueltank,theairconveyorandflywheelnut.Useextractorcod.00365R0020,asshowninfigure3.

Duringthedemountingphases,payparticularattentiontopreventtheflywheelfromdroppingasthiscouldseriouslyinjuretheoperator.Wearprotectivegoggleswhenremovingtheflywheelring.

IMPORTANT: Do not tap the end of the extractor whenremovingtheflywheel.

Removing the cover on the timing system sideSlackenoffthescrewsaroundtheperimeterofthecoveronthetiming system side. Split the cover from the engine casing byleveringwithascrewdriverinthepointsindicatedinfig.4.

Warning: to prevent damage to themain bearings, it isadvisable to demount the cover from the timing systemsidewiththeenginecold.


- 18 -

7

6

5

9

00365R0900

00366R0220

00365R0900

00366R023000366R0220

Disassembly of the engine

Demounting the pistonTakeoutthepistonpinasshowninfig.5.

Warning: do not demount the head when hot or theretentionsurfacescouldbedamaged.

Demounting and remounting the main bearingsUsetoolcode00365R0900andplugcode00366R0220 (fig.6)todemountthemainbearingsfromtheenginecasingandcoveronthetimingsystemside.To fit the main bearing back into the engine casing, use toolcode00365R0900withplugcode00366R0220andsleevecode00366R0230sideA(fig.7).Tomount themain bearing on the cover on the timing systemside, use tool code 00365R0900 with plug code 00366R0220andsleevecode00366R0230sideB(fig.7).

During the assembly operations, make sure that the bearingholesmatchtheoilductsbymakingreferencemarkswithafelt-tippen.Makesure that the referencemarkon thebearingedgepointstowards:-thecasinginterior-theouterpartofthetimingsystemcover.

WARNINGProceedwiththefollowinginspectionsafterassembly:

Cover on timing system sideThemainbearingmustproject1.7to2mminrelationtothebearingsurfaceofthebullring(innersideofcover).

Engine casingThemainbearingmustbeflushwiththebearingsurfaceoftheshimmingring(innersideofcasing).

Mainbearing

Mainbearing


- 19 - - 19 -

11

10

9

8

10

ØA ØB ØC1 ØC2 ØD1 ØD2 ØE(*) ØF1 ØF2 G

13÷

13,01

13,025÷

13,037

40,13÷

40,145

35,13÷

35,145

40÷

40,025

35÷

35,025

7÷

7,01

6,96÷

6,97

6,945÷

6,995

0,8÷1

CHECKS AND OVERHAUL

HeadPartsindicatedinfig.8.1.Nut-2.Nutwithball-3.Rockerarm-4.Cotters-5.Rockerarmstud-6.Uppercap-7.Spring-8.Air-reliefvalve-9.Lowercap -10.Valveguide -11.Rockerarmcover -12.Head -13.Valvehousing-14.Exhaustvalve-15.Intakevalve-16.Rockerarmrod-17.Camshaft-18.Tappets.Theheadismadeofaluminiumwithvalveguidesandhousingsin facedcast iron.Removeanycarbondeposits from theheadandcheckthecylinderbearingsurface.Levelitofftoadepthofnomorethan0.3mmifdeformed.Theheadmust not be cracked or deformed. If such faults arediscovered, replace the part after consulting the spare partscatalogue.

Do not demount the head when hot to avoiddeformations.

Valves - Guides - HousingsCleanthevalveswithametalbrushandreplacethemifthetopsaredeformed,crackedorworn(fig.9).

1=intake2=exhaust

(*)withguidemounted. measurementsinmm

Check thedimensionsof the valve stem (fig. 10) and theplaybetweentheguideandvalve.Reamtheguidetothedimensionsindicated in the table. Change the guide and valve if the playexceeds0.1mm.

The valve housings will always need to be ground when newguidesaremounted.Valveguidesoversizedon theoutsideby0.10mmareavailable.Aftertheenginehasbeenusedforalengthyperiodoftime,valveknocking in theirhousingsathigh temperatureswillharden thehousingtracksandmakemanualmillingdifficulttocarryout.When thishappens, remove thehardenedsurface layerwithagrinderat45°(Fig.11).

The valve retention trackwillwidenwhen the valvehousing ismachined. Final adaptation of the valve in the housing mustbecarriedoutbysmearingfinegrain lappingcompound in thehousingandturningthevalvewitha lightpressureandwithanalternatemovementuntilthesurfacesbedperfectly(fig.12).

Complywiththevalveembeddingvaluesasindicatedinthetable(G,fig.9).

Warning: when the valve embedding values are lowerthanthoseprescribed,thevalvescouldinterferewiththepiston.


- 20 -

15

14

13

12

10 Checks and overhaul

Grinding-in must always be carried out when new valves orhousingsaremounted.Valvehousingsoversizedontheoutsideby0.5mmareavailable.Thoroughly wash the valve and housing with petroleum orgasolinetoeliminatelappingpasteresiduesorswarf.Proceed in the followingway tomake sure that the valve andseataretight:

1.Mountthevalveontheheadwithcapstringandcotters(seefig.8)

2. Overturntheheadandpourafewdropsofdieselfueloroilontotheedgeofthevalvetop

3.Blowcompressedairintotheheadduct.Plugtheedgesoftheductitselftopreventairescaping.

Ifthereareairleaksintheformofbubblesbetweenthehousingandvalve,demountthevalveandgrind-inagain.

Valve springsCheckthe lengthof thespringas indicated infig.13to identifyanyyielding.Replacethespringsifthevaluesaredifferent.

Rocker armsMake sure that there are no evident signs of wear on thecontactingsurfaces.Replacethepartsifnecessary.

CylinderInspecialcastironwithintegralliner.Useaboregaugetocheckthetwointernaldiameters(C-D)perpendiculartoeachotherandatdifferentheights(fig.14).Maximumtoleratedtapererror(A-B)andovalityerror(C-D):0.06mm.

Cylinderdiameter:

Ø 87 ÷ 87,020

Ifthediameterofthecylinderdoesnotexceedsaidvaluesorifthereareslightsurfacescoresonthecylinder,itwillbesufficienttochangethepistonrings.

Donotmanuallyhonethecylinderboresurfaceswithemeryclothorothermeans.

Thecross-hatchpatternshouldbeatanangleof90°÷120°;linesshouldbeuniformandclearinbothdirections(fig.15).Averageroughnessmustrangebetween0.5mm1μm.Thecylindersurfacewhichcomesintocontactwithpistonringsshouldbemachinedwiththeplateaumethod.

Replace the cylinder and piston if there is a ridge in zone "X"fig. 15 of the cylinder and if tapering and ovality exceed thepreviouslygivenvalues.

Freelength


- 21 - - 21 -

19

18

17

16

10

0,30÷0,50 0,800,25÷0,50 0,80

A=0,22B=0,19C=0,16

21,997÷22,002 0,003÷0,013 0,040

21,997÷22,002 0,023÷0,038 0,070

Checks and overhaul

Piston rings - Piston - PinTogaugethewearonthepistonrings,putthemintothecylinderfromthebottomsideandmeasurethedistancebetweenthefreeends(fig.16),whichmustbe:

Makesure that thepiston ringsslidesmoothly in theslotsandusea thicknessgauge tocheck theplaybetween theslotandring(fig.17).Replacethepistonandringsiftheplayexceeds:

Pistonring Fittingmm Max.wearmmCompression

Oilscrapper

WARNING: it is advisable to replace the piston ringswheneverthepistonisdemounted.

Checking the piston diameter: the diameter of the pistonmust be measured at a distance from the base (fig. 18) ofapproximately11mm.

Ø 86,915 ÷ 86,835

Checktheplaybetweencylinderandpiston.Replacethepartsifplayexceeds0.150mm.Playbetweenpinandpistonmm:

Pistonring Max.wearmm1stCompression

2ndCompression3rdOilscrapper

PinØmm Assy.clearancemm Max.wearmm

PinØmm Assy.clearancemm Max.wearmm

Connecting rodCouplingbetweenthesmallendholeoftheconnectingrodandpinismadewithoutabearing.Playbetweenconnectingrodsmallendandpinmm:

Checkconnectingrodaxesparallelisminthefollowingway:

1. Insert the pin into the small end hole of the connecting rodand a calibrated plug into the big end (with the bearingmounted).

2.Rest theplugon twoprismsarrangedonasurfaceplateorbetweentwocenters(fig.19).

3. Use a centesimal comparator to check that the differencebetween the readings made at the ends of the pin doesnot exceed 0.02 mm. square up the connecting rod if thedeformationisgreater(max. 0.05 mm).


- 22 -

23

22

21

20

10

STDmm -0,25mmACB

41,97÷41,9939,98÷40

41,72÷41,7439,73÷39,75

Checks and overhaul

Theoperationiscarriedoutbyapplyingacalibratedpressuretotheconvexsideinthemiddleoftheconnectingrodstemsetonsurfaceplates(fig.20).

Crankshaft Itisadvisabletochecktheconditionofthecrankshaftwheneverthe engine is demounted and particularly when cylinders andpistons must be replaced following wear due to dust havingbeenintaken.Thoroughlycleaninsidetheoilductsusingashapedmetalpoint.Ifthereareheavilycakedincrustations,immersethecrankshaftintoabathofpetroleumorgasolinebeforeproceedingwiththescrapingoperation(fig.21).Whenthecrankshaftisperfectlyclean,checkwithamicrometerto ascertain wear and main journal ovality in the twoperpendicularpositions(fig.22).Grind the shaft if thewear exceeds the values in the table by0.08mmormore.

Undersizedbearingscanbemountedwithoutanyreamingworkrequired.

WARNING:donotremovematerialfromthemainjournalshims during the grinding operation as this wouldalter crankshaft float. Also make sure that the grinderradii correspond to those indicated in fig. 21 to preventfracturesectionsfrominitiatingontheshaft.

Oil retention ringsMakesure that theringshavenothardened in theretention lipandthatthereisnosignofbreakageorwear.

Lubrication circuitLubricationof themainbearingsandconnecting rodbigend istheforcedtypewitharotoroilpump.Excessivepressureintheoilcircuitispreventedbytheby-passvalve(3,fig.23).Alltheotherpartsaresplashlubricated.Oil vapours are eliminated from inside the casing by adiaphragmmountedintherockerarmcover.

Illustrationinfig.23:1. Internal intake oil filter in casing -2.Oil pump -3. By-passvalve-4.Engineoilfilter-5.Pressureswitch-6.Mainbearing-7.Bigendbearing.

Dimensions

NOTE: crankshaft grinding operations of more than 0.25 mm should not be carried out.


- 23 - - 23 -

27

26

25

24

10

C Ø25,97÷25,99 Ø25,92D Ø34,96÷34,99 Ø34,87E 26,205÷26,27 26,31F 7,97÷7,99 7,93

0,16÷0,215 0,345

0,03÷0,07 0,11

Checks and overhaul

Checking the oil pumpMakesurethattheoilpumpcoverisinagoodcondition.Afterdemounting,examine the rotorsand replace them if theirlobesorcenteringsaredamaged.Tocheckthedegreeofpumpwear,measure thedimensionsofrotor Aandrotor B (fig.24)andcomparethemwiththevaluesinthefollowingtable:

OILPUMPROTORDIMENSIONSANDPLAY

Theentirepumpmustbereplacedifthewearisgreater.

Thecouplingplaybetween theexternaloil pump rotorand thehousingonthecoverofthetimingsystemis:

Makesurethattheoilpumprecessinrelationtothesurfaceofthetimingsystemcover(fig.25)isbetween:

CamshaftMake sure that the cams and bearing pins are not scored orworn.Checkthedimensionsasindicatedinfig.26.Check the dimensions of the camshaft pins (D, fig. 27) andthecorrespondinghousingsinthecasingandcoveronthetimingsystemside.Themax.xonstructionalplayis0.032to0.061mm.

WARNING:replacetheshaft if thewearonthecamsorpinsexceeds:0.1 mm(injectioncamsandpins)0.3 mm(intakeandexhaustcams).

Rotor A Rotor B

IntakeExhaust

Injection

A.C.P

UMP

INTA

KE

INJECTION

EXHAUST

Measurement Dimensionsmm Max.wearmm

Fittingmm Max.wearmm


Make sure that there are no impurities in the by-pass valveon the cover on the timing system side by unscrewing theinspectionplugnearthefuelflowlimiter.


- 24 -

29

28

10

0,021÷0,059 0,10

53,0÷53,2 0,3 1,45÷2,05

Checks and overhaul

Tapets and rocker armsMake sure that there is no wear, scoring or signs of seizureon the surfaces of the tappets (fig. 28). Replace the parts ifnecessary.Tapetandhousingcouplingplay:

Injection pump tappets and padsReplacethepartsifthewearontheirsurfacesexceeds0.1mm(fig.29).

Coupling play between the tappet and relative housing in thecrankcase:

Fuel pump (optional)ChecktheprojectionoftheACpumprodinrelationtotheenginecasingsurfacewith thecanshafteccentric in thenon-operativeposition.

0,16÷0,215 0,345Fittingmm Max.wearmm

Therodsmustbestraightwithballshapedsurfacesattheendsandingoodconditions(fig.28).


WARNING:therodprojectioncannotbeadjusted.

Rodlengthmm

Wearlimitmm

Rodprojectionmm


- 25 - - 25 -

31

30

11INJECTION EQUIPMENT

Fuel circuitFuel supply is the gravitational type. An AC pump can bemountedonrequest.Airbleedingisautomatic.

Illustrationinfig.30:1.Fueltank-2.Fuelpipe-3.Fuelfilter-4.Injectionpump-5.Fuelreturnpipe-6.Injector-7.Injectionpipe-8.Fuelpipe.

Injection pump

Illustrationinfig.31:1.Deliveryunion-2.Filler -3.Valvespring-4.Deliveryvalve-5.Washers-6.Monoblocpumpcasing-7.Adjusterseal -8.Flange-9.Pumpseal -10.Plunger-11.Adjustersleeve-12.Plug-13.Adjusterblock-14.Spring-15.Lowercap


- 26 -

35

34

33

32

11 Injection equipment

Checkingtheinjectionpumpbefore demounting the injection pump, make sure that theplungerunit,enblocpumpcasingandvalvearepressuretightbyproceedinginthefollowingway:1.Connectapressuregaugewithscaleupto600 Kg/cm²tothe

fueldeliverypipe(fig.32).2. Set the regulating sleeve (fig. 33) to the average delivery

position.3. Slowly turn the flywheel to make the plunger make one

compressionstroke.4.Readtheindicationonthepressuregauge.Ifit islowerthan

300 Kg/cm²,thecompletepumpmustbechanged.

During the test, the pressure gauge needle will show aprogressivepressure increaseuntil reachingamaximumvalue,afterwhichitwilldropsharplybackandstopatalowerpressurevalue.Replacethevalveifthepressuredropismorethat50 Kg/cm²andcontinuestoslowlydroplower.Thepressuremustdropfrom200 Kg/cm²to150 Kg/cm²innotlessthan7 sec.

Injection pump calibration (fig. 34)When the adjuster sleeve is 10.5 mm from the stop positionandthepumpspinsat1,500 rpm, theamountof fuel for1,000deliveriesmustbebetween:

25,5 ÷ 29 cc

Replacethepumpifthevaluesdiffer.

WARNING:Checktomakesurethatplungertravelwiththeinjectioncamsinthenon-operativeposition(BDC)atthestartofdeliveryis:

25,5 ÷ 29 cc

Injection pump assembly (fig. 36)Iftheinjectionpumpmustbedemounted,useanelectricpentomarktheadjusterblock(M)withtheenblocpumpcasing(A)andloosen the plug (N) after having heated it tomake the Loctiteeasiertorelease.

Comply with the following instructions when remounting theparts:1.Fitthewasher(B),thedeliveryvalve(C),thewasher(D),the

alvespring(E), thefiller(F) intotheenblocpumpcasing(A)andtorquethedeliveryunion(G)toavalueof:

4,3 ÷ 5,4 kgm (42,5 ÷ 52,5 Nm)

2.Inserttheadjusterseal(H).3.Inserttheflange(I).4. Insert theplungerwithhelicalprofile(A,fig.35) intothe iner

housing of the adjuster sleeve from the side opposite thesleevepin(B,fig.35).


- 27 - - 27 -

39

38

37

36

11

0,24 5 0,25

Injection equipment

5. Insert theadjustersleeveunitandplunger(L) intothepumpcasing(A),makingsurethatthehelicalprofileisdirectedonalevelwiththereturnunionwithball.

6. Fit in the adjuster block (M), matching the referencemarksappliedduringthedemountingphase.

7.Tighten theplug (N) to a0.5 to0.6Nm torque, locking it inplacewithLoctite290.

8.Insertthespring(O)andlowercap(P).9. Compress the tappets in the various operating positions to

checkthattheadjustersleeve(L)slidesperfectly.Resistanceorjammingwillmaketheenginetohuntduringoperation.

Leak testPlug the fuel return union and let air in through the fuellingunionatapressureof6 Kg/cm².Fully immerse thepump inareceptaclecontainingdieselfuelforabout50-60seconds(fig.37)andmakesurethatnobubblesappear.

NOTE: the position of the pump adjuster sleeve is of noimportanceforthistest.

InjectorDetailsoffig.38:1. Filter -2. Fuel inlet union -3. Fuel returnunion -4.Nozzleholder-5.Calibrationwasher-6.Spring-7.Pressurerod-8.Spacer-9.Nozzle-10.Ringnut.

Injector inspection and calibration1.Cleanthenozzleholeswithathinsteelwire(fig.39)withthe

followingdiameters:

2.Mount the injectoronthetestbench(code00365R0430,fig.40).

Disconnectthepressuregaugeandrapidlyoperatethelever.Thenozzlemustmake thecharacteristic "trilling"soundandinjectwithagoodatomizingaction.

3. Connect the pressure gauge. Slowly depress the level in acontinuouswayuntilinjectionoccurs.

Theinjectorneedlemust"open"atthepressureof230to238bar.Vary thewasher shims (N°5 fig. 38) to calibrate in thecorrectway.

4.Leak test:operatethetestbenchleveruntilthegaugepointeris 20 Kg/cm² below the injection pressure value. Nozzletightnessisgoodifnofuelcomesoutwithin10sec.

5.Checking for leaks on the nozzle return phase:operatethetest bench lever until the gauge pointer is 20Kg/cm² belowtheinjectionpressurevalue.Releasetheleverand

Diameterofsteelwire(mm)

Numberofholes

Diameterofholes(mm)


- 28 -

41

40

11heckthetimeittakestodrop.Thepressuremustdropto150to100Kg/cm²withinn6to40seconds.-replacethenozzleifitdropsinlessthan6seconds.-ifittakeslongerthan40secondstodrop,makesurethattherearenocarbondepositsinthenozzleandthatthereturnholesarenotclogged.

DemountingandremountingLoosentheringnutthatfixesthenozzleusingatorquewrenchandasdevice like theone shown in fig. 41which relieves thepressureexercisedbythespringontheringnut.

1. Visual inspection:makesurethattheneedlehousingisnotdeformedorexcessivelyrough.Thenozzlebodymustnotshowsignsofwearordamage.Theholesmustbefreefromcarbonresidues.

2. Smoothness test: the nozzle needle,whichwill have beenpreviouslyimmersedinimpurity-freefuel,shouldbeinsertedintothebodyofthenozzle.Nozextractitbyuptoathirdoftheguidelength,holdingthenozzleinaverticalposition.Theneedlemustdropbackintoitshousingthankstoitsactualweightalone.

Remount the injection in compliance with the order indicatedin fig. 38.Make sure that the plugs and centering pins on thespacer (N°8 fig. 38)match the relative holes in the housings.Tightentheringnutthatfixesthenozzletoavalueof:

4,6 ÷ 5,6 kgm (45 ÷ 55 Nm)

Injection equipment


- 29 - - 29 -

44

43

42

12Characteristics of the system

Starter motor: lh rotation direction (pinion side), 12V voltagerating,power1.1kW.

Internal alternator:12V-280W

Voltage regulator: electronic, with controlled diodes andindicatorconnectionforbatteryrecharger

Recommended battery:Instandardstartconditions:12V-50Ah/255ADINInheavy-dutystartconditions:12V-60Ah/300ADIN

Optional accessories: control stripwith remote control switchandOILALARMplant.

Illustrationinfig.42:1. Ignition key - 2. Voltage regulator - 3. Starter motor - 4.Battery - 5. Alternator - 6. Pressure switch - 7. Low batterychargeindicator-8.Lowoilpressureindicator.

CABLES:ColourxSectionmm2

CABLECOLOURS: B=white M=brown N=black R=red V=green

Checking the system

1. make sure that the connections between the regulator andalternatorarecorrectandingoodconditions

2. detach the wire from the remote control switch from theterminalandfitonad.c.amperometer(A,fig.43)

3.connectad.c.voltmetertothebatteryterminals(V,fig.43)

4.makeafewno-loadstartsorintroducea80-100Wlamploadatthebatterylugstokeepthebatteryvoltagebelow13V.

5. accelerate the engine to a 3000 rpm rate. The currentindicatedontheamperometermustcorrespondtothevaluesinfig.44.

6. disconnect the load (if any) and keep the engine at theabovementionedrateforafewminutes.Thebatteryvoltagemust progressively increase until reaching about 14.2 V.Meanwhile,thechargevoltagemustdroptoaminimumvalueofabout2A,withaspeeddeterminedby thebatterychargecondition.

7. if chargecurrent ismissingor is less than thegivenvalues,check the alternator and replace the voltage regulator ifnecessary.

ELECTRICAL EQUIPMENT


- 30 -

47

46

45

12Checking the alternatorWith the engine at a standstill, disconnect the alternator wiresfromtheregulatorandcheck:

1.usinganohmmeter,thatthewindings(fig.45,nullresistance)andtheinsulationbetweenwiresandground(fig.46, infiniteresistance) are unbroken. Replace the stator if interruptionsarediscovered;

2. with a voltmeter, the voltage between the two yellow wires(fig. 47). Accelerate the engine to 3000 rpm. The voltagemustbe33V.

If thevaluesaremorethan10Vlessthanthis, itmeansthatthe rotor is demagnetized and that the alternator must bereplaced.

Warning:1.thealternatordoesnotdelivercurrentwhentheyellowcablesareisolated

2. the alternator burns out if the yellow wires aregrounded

3. the regulator may be damaged if the groundconnection or electrical connections are made in aslapdashway.

4.thealternatorandregulatorwillimmediatelyburnoutifthebatteryconnectionsareinverted.

Ring gearMake sure that the teeth of the crown wheel are not worn ordamaged.Heat the starting ringgear to a temperatureof 200-250°Cbeforefittingitontotheflywheel.

Electrical equipment


- 31 - - 31 -

51

50

49

48

13The instructions refer to engines updated at the timeof publication. Check the technical circulars for anymodifications.Thoroughlycleanthepartsbeforeremountingthem.Lubricatethemovingpartstopreventseizureswhentheengineisfirststarted.Replacethesealswheneverthepartsareremounted.Usetorquewrenchestotightentothecorrectvalues.

Preparing the engine blockRemove all traces of sealant or impurities from the bearingsurfaceswitha copperplateor lapping stone, thenproceed inthefollowingway:

1. Fit on the oil drain plugs without tightening them toomuch(max.2Kgm)topreventdamagetothethreads.

2.Mountthemainbearingasindicatedatpage18.

3.Fit thebenzingringon to thepinof theregulator levers (fig.48-A);applyLoctite648tothezonewherethepintouchestheenginecasing.

Insert the stop lever (fig. 48 -B), the accelerator lever (fig.49-C)andcompletetheassemblyoperationsincompliancewiththesequenciesindicatedinfigures48and49.

4. Comply with the sequence indicated in fig. 50 for the"motorstop"version.

Injection pump tappetsInsert the tappet into the injectionpumphousing in theenginecasing.Fitthescrewintotheguideasshowninfig.51.

ENGINE ASSEMBLY


- 32 -

55

54

53

52

13 Engine assembly

Timing system cover pre-assembly

Preparethecoverofthetimingsysteminthefollowingway:

1.Mountthemainbearingasindicatedatpage18.

2.Fitinthepinanddriveshaftbearingring(fig52).

3.Mounttheoilpumprotorsasdescribedatpage23.Insertthepluganddrivingpinasshowninfig.53-A.Fixtheoilpumpcoverinplacebytighteningthescrewstothefollowingtorquevalue:

0,8 ÷ 1,0 kgm (7,8 ÷ 9,8 Nm)

4.Inserttheby-passvalveusingtoolcode00366R0210(fig.54);mount theby-passcheckscrewwithLoctite648;mount thebypassvalve inspectionplugon theoutsideof thecoveronthetimingsystemside.

5.Fit the retainercapon theoil intakeductat thebaseof thecoveron the timingsystemside,usingLoctite648 (fig.53 -B).

6.Tightentheinternaloilfilter(fig.53-C).

7. Fit on the engine oil filter and relative plug including theO-Ring(fig53-D).

8.Mount therpmgovernor, incompliancewith thealphabeticalsequencegiveninfig.55.

9.Fitinthefuelflowlimiter

10.Mounttheoilretentionringasindicatedonpage35fig.66.


- 33 - - 33 -

59

58

57

56

13Engine assembly

Removal and assembly of the drive shaft gearThegearonthetimingsystemsidecanonlybereplaced.

Todemountit,usepullercode00365R0100(fig.56)orapulleravailableonthemarket.

Toassemble,preheatthegeartoatemperatureofabout180to200°C,fititontheshaft,takingcaretoensurethatthechamferpointstowardstheinternalpart,andusethetangasareference.

Drive shaft assembly (fig. 57)Mount the drive shaft after having fixed the first shimmingwasher to thecasingwithLoctite648andafterhaving insertedtheneedlebearingandthesecondshimmingwasher.

Connecting rod - drive shaft connection Afterhavingfitted thebearings into thesmallend, connect theconnectingrodtothecrankpinasshowninfig.58.Mount the connecting rod cap with the reference numbersmatchingthoseontherod.

WARNING: mount the connecting rod half bearingwith the positioning mark on the cap and that withoutpositioningmark in the center of the rod, in compliancewiththedimensionsindicatedinfig.58.

Evenlytightentheconnectingrodboltstothefollowingvalue:

3,8 ÷ 3,9 kgm (37,3 ÷ 38,2 Nm)

Counter-shaftInsert the counter-shaft, matching the reference marks on thegears(fig.59).


- 34 -

63

62

61

60

13CamshaftInsert the tappets into their housingson thecasing.Mount thecamshaft,matchingthereferencemarksonthegears(fig.60).

Play adjustmentCrankshaft float:Placeacalibratedbaronthecasing,ona levelwith thetimingsystem cover retention surface and use a thickness gauge tocheck the distance between the gear and bar (fig. 61). Notedownthevaluemeasured.Place a calibrated bar on the cover of the timing system, ona level with the engine casing retention surface and use athicknessgaugetocheckthedistancebetweenthebearingringandbar(fig.62).Notedownthevaluemeasured.Thesumofthetwomeasuredvaluesmustbewithin:

0,10 ÷ 0,30 mm

Camshaft float:

Placeacalibratedbaron thecasing,ona levelwith the timingsystemretentioncoveranduseathicknessgaugetocheckthedistancebetweenthegearandbar(fig.63).Thevaluemustbebetween:

0,10 ÷ 0,25 mm

Engine assembly


- 35 - - 35 -

67

66

65

64

13Counter-shaft float (optional):

Place a calibrated bar on a levelwith the timing system coverretention surface and use a thickness gauge to check thedistance between the stop surface and bar (fig. 64). Themeasuredvaluemustbebetween:

0,10 ÷ 0,25 mm

Cover on timing system sideSpread liquidsealof theAREXOND0036MOTORSILtypeontheretentionsurfaceofthetimingsystemcover(fig.65).Placethecoveronthecasing.Insert thecoverfixingscrews,makingsurethat thefiveshorterones(40mm)aremountedinthetoppartofthecover.Tightentothefollowingtorquevalue:

2,7 ÷ 2,8 kgm (26,5 ÷ 27,5 Nm)

Oil retention rings

1. Immersetheretentionringinoilforabout10minutes.2.Cleanthehousingand insert theringwithaplug,exercisinganevenpressurealloverthesurface(fig.66).

FlywheelBlocktheflywheel(fig.67)andtorquethenuttovalue:

18 ÷ 20 kgm (176,5 ÷ 196,1 Nm)

Engine assembly


- 36 -

71

70

69

68

13

0,00÷0,10 0,80,10÷0,20 0,90,20÷0,30 1,00,30÷0,40 1,1

PistonMounttheringsonthepiston(fig.68)inthefollowingorder:1. chromium plated compression retention ring (stampedtrademarkpointingupwards)

2.taperingretentionring(stampedwordTOPpointingupwards)3.oilscraperring(stampedtrademarkpointingupwards)

Position the piston so that the central axis of the combustionchamberisalignedwiththeinjector(fig.69).Connectthepistontotheconnectingrod,slightlypressingwiththehandonthepin.

CylinderInsert the cylinder into the engine casing after having insertedthe0.3mmthickseal.beforemounting, turntheringsthrough120°,one inrelationtotheother,with thefirst compression ringpointingwith itsendsonalevelwiththepinaxis.There isa chamfer toallow ring insertionon the lower sideofthecylinder.Theoperation issimplifiedbyusinganormal ringmountingtoolcode00365R0770asindicatedinfig.70.Move the piston toTDC (top dead center) and check that themark stamped on the flywheel corresponds to the referencepointerofthetoolcode00366R0240(fig.75).

To obtain the correct clearance, use a head seal of adequatethickness:1. checkthepistonprojectionasshowninfig.712. Choosethesealasindicatedinthefollowingtable

HeadBefore fixing the head to the cylinder, fit the injector into itshousing and, after having temporarily fixed it, check that thedistancethenozzleprojectsfromthesurfaceoftheheadby(fig.72):

2,2 ÷ 2,7 mm

regulatebyplacingcopperwashersbetweentheinjectorandthebearingsurfaceonthehead.Consult page 19 and 20 for the relative inspections andoverhauls.

Engine assembly

Measurement Dimensionsmm

NOTE: The distance between piston crown and thecorrespondingheadsurfacemustbe:

0,7 ÷ 0,8 mm


- 37 - - 37 -

75

74

73

72

13

0,20mm

0,20mm

hot

cold

(intake/exhaust)

(intake/exhaust)

3000 18°(42,4mm)3600 23°(54,2mm)

Thepunchmarksontheflywheelindicate(fig.75):

TDC=topdeadcenterIP =startofdelivery

Inserttherockerarmcasings,thepartition(A,fig.74),theheadseal and the head. Tighten the head fixing nuts evenly andalternately(fig.73)tothefollowingvalue:

4 kgm (39,2 Nm)

NOTE:Topreventoil leaks,apreadsealant(Motorsil)onthethreadsofthestudboltsandwasherbearingsurfacesintherockerarmchamberbeforetighteningthenuts.

Valve clearanceAdjusttheclearancebetweenvalvesandrockerarmsineitherahotorcoldcondition,tothefollowingvalues(fig.74):

Engine assembly

Since the automatic decompression device opens the exhaustvalve near TDC, clearance must be adjusted during theexpansionphase,afewdegreesafterTDC.

Injection leadToensuretheinjectionleadisaccuratelyadjusted,itisadvisabletodefine theshims to insertunder thepumpbymeasuring thedimensionbetweenthepumpbearingsurfaceandthetappet.Proceedinthefollowingway:

1. turntheflywheeltothecompressionphase2. insert the tappet pad into the housing in the engine block,pointingtheexhaustsidetowardsthetappetroller(seefig.29page24)

3.align thedynamic leadpunchmark (IP)on theflywheelwiththereferencemarkofthetoolcode 00366R0240(fig.75)

4. using a depth gauge (fig. 76), measure the dimensionbetween the injection pump bearing surface and the tappetpad.

5. subtract 51.6 mm from the dimension measured on thegauge; the result represents the theoretic thickness of thesealstoinsertundertheinjectionpump.

NOTE:if theflywheeloracrankcomponent isreplaced,makesurethatthepunchmarkontheflywheel(TDC,fig.75)andthereferencemarkofthetoolcode00366R0240,matchwhenthepistonisattopdeadcenter.

Leadvaluesindegreesandmillimetersontheflywheel:

rpm Lead IP


- 38 -

78

77

76

13Mounting the injection pump on the engineLowerthetappetintheinnermostpointoftheenginebyslightlyturningtheflywheel.

-Insertasealofadequatethickness(seesection"Injectionlead"point5,page37).

-TurnthemotorstoplevertotheSTOPposition.- Set the adjuster sleeve of the injection pump about onemillimeterfromthestoppositionontheadjusterblock(fig.77).

- Fit the injection pump into the engine block and, keeping itpressed down, fix it in place by tightening the nut that holdsthe relative bracket. (Match the marks made during thedemountingphase,seesection"Removingtheinjectionpump"page17)

Warning:consultsection"Brakedenginetest"page39,ifthepositionoftheinjectionpumpinrelationtothecasingwasnotmarkedduringthedemountingoperationsorifanewonemustbeinstalled.

Injector and injector tubeMount the injector on the head, inserting the copper retentionseals(seesection"Head"page36).Connecttheinjectortothepumpwiththeinjectionpipe.

Warning: always use two wrenches to slacken off ortighteninjectionpipes(fig.78)

Engine assembly


- 39 - - 39 -

81

80

79

14

5 2000 015 3000/3600 030 3000/3600 30%30 3000/3600 50%30 3000/3600 70%5 3000/3600 100%

Time(min) RPM Load

Rpm regulationFilltheenginewithoilanddieselfuelandallowittowarmupfor10minutes.With the enginehot, adjust the idling rate (A, fig. 79) to1,300 rpmandthepeakno-loadrate(B,fig.79)to:-3,150 rpmforenginessetat3,000rpmonload-3,750 rpmforenginessetat3,600rpmonload

Braked engine testCarry out the following operations after having positioned theengineonthebrake:1.Starttheengineandallowittoidle2. Allow the engine to run in before checking the maximum

power

Running-intable

There may be hunting problems, slowness or misfiring if theinjection pump is changed. Correct these faults by turning thepump casing a few degrees in relation to the engine casing,followingthedirectionsindicatedinfig.80.

Fuellimiter.The fuel limiter has a torque corrector device (fig. 81) thatconsistsofthefollowingparts:

A)TorquecorrectorcapB)MaximumpowerflowrateadjusterC)SpringloadadjusterD)Lockingnuts

The adjustments can only bemade to the exhaust brake. It isthereforeinadvisabletotamperwiththecorrectoradjuster(Cfig.81). The setting of adjusterB (fig. 81) can only bemodified ifwork has been done on the injection pump or regulator, if theengineproducesalotofsmokeorhasinsufficientpower.

HUNTINGRATEDIMINISHES

RATEDIMINISHES

MORESLOWLY

ENGINE TESTING

Consultthepowercurvesinchapter5.


- 40 -

15 STORAGE

Storage

Prepareenginesasfollowsforstorageover30days

Temporary protection (1/6 months)

•Letenginerunatidlingspeedinno-loadconditionsfor15minutes.•FillcrankcasewithprotectionoilMIL-1-644-P9andletenginerunat3/4fullspeedfor5/10minutes.•Whenengineiswarmemptyoilpanandfillwithstandardnewoil•Removefueltubeandemptythetank•Removefuelfilter,replacecartridgeifdirtyandrefit•Carefullycleancylinderfins,headsandfan•Sealallopeningswithtape.•Removeinjectors,pouraspoonfulofoiltypeSAE30intothecylindersandrotatemanualytodistributetheoil.Refitinjectors.•SprayoiltypeSAE10Wintoexhaustandintakemanifolds,rockerarms,valves,tappetetc.Greaseallunpaintedparts.•Loosenbelt•Wraptheengineinaplasticfilm.•Storeinadryplace,ifpossiblenotdirectlyonthesoilandfarfromhighvoltageelectriclines.

Permanent protection (over 6 months)

•Thefollowingisrecommendedapartfromtheaboveinstructions:•ForthelubricationandinjectionsystemaswellasformovingpartsuserustproofoiltypeMIL-L-21260P10grade2,SAE30(Ex.ESSORUST-BAN623-AGIP,RUSTIAC.SAE30)Lettheenginerunwithrustproofoilanddrainanyexcess.

•CoatexternalunpaintedsurfaceswithantirusttypeMIL-C-16173D-grade3/Ex.ESSORUSTBAN398-AGIP,RUSTIA100/F).

How to prepare the engine for operation

•Cleanengineoutside•Removeprotectionsandcovers•Removeantirustwithanappropriatesolventordegreaser.•Removeinjector,fillwithstandardoil,turncrankshaftbyafewrevolutions,removeoilpananddraintheprotectiveoil.


- 41 - - 41 -

16

XVI 0,032÷0,061

0,030÷0,050

0,025÷0,050

0,023÷0,038

0,021÷0,059

0,005÷0,029

0,003÷0,013

0,030÷0,050

0,045÷0,065

0,1

0,8

0,8

0,04

0,1

0,1

0,04

0,1

0,1

MIN (mm)0,1

0,1

0,1

0,3

0,15(0,20)

0,8

2,2

0,1

MAX (mm)0,25

0,25

0,3

0,5

0,15(0,20)

1

2,7

0,4

QUICK REFERENCE CHARTS

Adjustments

Camshaftfloat

Countershaftfloat

Crankshaftfloat

Connectingrodfloat

Valveclearancehot[cold]

Valverecessing

Injectorprojection

Pistonprojection

Couplings

Camshaftandplugs

Compressionringopening

Oilscraperringopening

Connectingrodandpistonpin

Injectionpumptappetsandhousing

Tappetsandhousing

Pinandpiston

Intakeguideandvalve

Exhaustguideandvalve

Spiel (mm) Grezen (mm)


- 42 -

= 8.88.8

= R10 = 10.9R10

= R12 = 12.9R12

kgm0,52

1,01

1,73

2,84

4,25

5,45

7,54

12,80

19,40

29,50

37,00

51,50

62,40

80,00

Nm5,1

9,9

17

27,8

41,6

53,4

73,8

125

190

289

362

504

611

784

kgm0,62

1,22

2,08

3,40

5,10

6,55

9,05

15,30

23,30

35,40

44,40

61,80

74,90

96,00

Nm6

11,9

20,4

33

50

64.2

88.7

150

228

347

435

605

734

940

R ≥ 800 N/mm2 R ≥ 1000 N/mm2 R ≥ 1200 N/mm2

Nm3,6

7

12

19,8

29,6

38

52,5

89

135

205

257

358

435

557

kgm0,37

0,72

1,23

2,02

3,02

3,88

5,36

9,09

13,80

21,00

26,30

36,60

44,40

56,90

4x0,70

5x0,80

6x1,00

7x1,00

8x1,25

9x1,25

10x1,50

13x1,75

14x2,00

16x2,00

18x2,50

20x2,50

22x2,50

24x3,00

XVIkgm

2,7÷2,8

4,6÷5,6

2÷2,5

0,8÷0,9

2

4

18÷20

3,8÷3,9

(Nm)26,5÷27,5

45÷55

19,6÷24,5

7,8÷8,8

19,6

39,2

176,5÷196,1

37,3÷38,2

16 Quick reference charts

Standard screw tightening torques

Denomination

Diameterxpitchmm

Tightening torques

Timingsystemcover

Injectorringnut

Injectiontubeunions

Injectorbracket

Injectionpumpbracket

Head

Flywheel

Connectingrod


- 43 - - 43 -

17

PMS

PMS

Fig. 1

Fig. 2

3000 2,735mm 18°3600 4,427mm 23°

2,443mm 17°

2,735mm 18°

3,043mm 19°

3,336mm 20°

3,704mm 21°

4,058mm 22°

4,427mm 23°

4,811mm 24°

SUGGESTIONS ON HOW TO TIME THE INJECTION PUMP WHEN THE LEAD PUNCH MARKS ON THE FLYWHEEL ARE DIFFICULT TO REACH.(Consultchapter"Injectionlead"onpage37foradescriptionoftheconventionaladjustment)

Proceed in the following way:1.Removethecoverfromtherockerarms.2. Demount the recoil and turn the drive shaft to the valve

regulationposition. (This operation is carried out bymeans of the fylwheel nut,

usingaN°32socketwrench).3.Demount the intakeorexhaust rockerarm, thevalvespring

andcaps.4.RestthevalvetoponthecrownoftheT.D.C.balancedpiston

(fig.1). WARNING: The valve slips from its guide if the piston is

lowered by turning the drive shaft more than 1/4 of a pipe wrench turn.

5. Position a comparator mounted on a magnetic pedestal ordummyinjectorandresetitonthevalvestem(fig.1).

6.Slowly turn thedriveshaft inananti-clockwisedirectionandcheck the comparator to make sure that the piston dropsabout5mminrelationtoTDC(dimension"h"-fig.2).

7.Slowlyturnthedriveshaftinaclockwisedirectionandcheckthe comparator to make sure that the piston rises by thevalues indicated in the following table, in relation to TDC(dimension"h"-fig.2):

8. Removetheinjectiontubeandmountthecapillarytubecode00365R0940ontheinjectionpumpdeliveryfitting(fig.3).

9. Turn theaccelerator lever to theMAXpositionand thestoplevertoabouthalftravel.

10.Turnthedriveshaftanti-clockwisebynomorethan1/4ofthepipewrenchturn.

11.Pressurizethecircuitbyturningthedriveshaftseveraltimesinanalternateclockwise/anti-clockwisewayuntil fuelsplashesoutofthecalibratedholeofthecapillarytube.

12. Turn the drive shaft and check the comparator to makesure that the piston drops about 10 mm in relation to TD.(dimension(quota"h"-fig.2).

13.Shakethecapillarytubeuntilanairbubbleformsinsideit(fig.3).

14.Turn thedriveshaft inaclockwisedirectionveryslowlyandcheck the position of the air bubble in the capillary tube.Asmall movement of this bubble will indicate the exact leadposition. This value must correspond to the one previouslyreadonthecomparator(seepoint7). If this isnotthecase,addorremovesealstoorfromtheinjectionpumpaccordingtothecorrectionsindicatedinthefollowingtable:

Capillarytube

TDC =topdeadcenterh=extentofpistonloweringinrelationtoTDC.α=anglecorrespondingtopistonloweringinrelationtoT.D.C.I.P. =startofdelivery

Airbubble

Injectionpump

SERVICE

rpm h α

rpm Lead IP


ENGINEDIVISION,KOHLERCO.,KOHLER,WISCONSIN53044

FORSALESANDSERVICEINFORMATIONINU.S.ANDCANADA,CALL 1-800-544-2444KohlerEngines.com

FORMNO. ED0053029390

ISSUED 04/07/2012

REVISED 00 DATE 04/07/2012

Translated from the original manual in Italian language.

Data reported in this issue can be modified at any time by KOHLER.

workshop manual kd 500 - lombardini s.r.l....kohler co. warrants to the original retail consumer...

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